Method of manufacturing rotary electric machine armature

ABSTRACT

A method of manufacturing a rotary electric machine armature that includes a cylindrical armature core in which a plurality of slots that extend in an axial direction are disposed in a circumferential direction and a coil wound around the armature core, the slots having respective radial openings that open in a radial direction, and the coil being formed by joining a plurality of segment conductors to each other.

BACKGROUND

The present disclosure relates to a method of manufacturing a rotaryelectric machine armature that includes a cylindrical armature core inwhich a plurality of slots that extend in the axial direction aredisposed in the circumferential direction and a coil wound around thearmature core.

There is already known a technique of constituting a coil of a rotaryelectric machine armature by joining a plurality of segment conductorsto each other. For example, Japanese Patent Application Publication No.2015-023771 discloses a rotary electric machine armature (stator 10)that includes a coil constituted by joining first segment conductors(first-side conductor segments 28) disposed on one side of an armaturecore (stator core 14) in the axial direction and second segmentconductors (second-side conductor segments 29 and 30) disposed on theother side of the armature core (stator core 14) in the axial direction.In the rotary electric machine armature (stator 10) according toJapanese Patent Application Publication No. 2015-023771, projectingportions (projecting portions 60) are formed at the distal end portionsof conductor side portions (first-side leg portions 32 and 33) of thefirst segment conductors (first-side conductor segments 28), andrecessed portions (recessed portions 62) are formed at the distal endportions of conductor side portions (second-side leg portions 40 and 41)of the second segment conductors (second-side conductor segments 29 and30). The first segment conductors (first-side conductor segments 28) andthe second segment conductors (second-side conductor segments 29 and 30)are joined to each other by being heated while being pressed from bothsides in the axial direction with the projecting portions (projectingportions 60) and the recessed portions (recessed portions 62) engagedwith each other.

In the rotary electric machine armature (stator 10) according toJapanese Patent Application Publication No. 2015-023771, however, thesegment conductors are pressed from both sides in the axial direction,and therefore only coils contact each other and it is difficult toposition the segment conductors for joining. Hence, it is difficult toappropriately join the first segment conductors (first-side conductorsegments 28) and the second segment conductors (second-side conductorsegments 29 and 30) to each other.

SUMMARY

Thus, it is desirable to achieve a technique that facilitatesappropriately joining segment conductors to each other.

In view of the foregoing, the present disclosure provides a method ofmanufacturing a rotary electric machine armature with a characteristicconfiguration, that is, a method of manufacturing a rotary electricmachine armature that includes a cylindrical armature core in which aplurality of slots that extend in an axial direction are disposed in acircumferential direction and a coil wound around the armature core, theslots having respective radial openings that open in a radial direction,and the coil being formed by joining a plurality of segment conductorsto each other, the method including: preparing a plurality of thesegment conductors and preparing the armature core, the segmentconductors having respective conductor side portions that extend alongthe axial direction and respective crossover portions connected to theconductor side portions on an outer side of the armature core in theaxial direction, the conductor side portions being provided withrespective joint portions that have respective facing surfaces;arranging, when the segment conductor, among the plurality of segmentconductors, the crossover portion of which is disposed on one side inthe axial direction with respect to the armature core, is defined as afirst segment conductor and the segment conductor, the crossover portionof which is disposed on the other side in the axial direction withrespect to the armature core, is defined as a second segment conductor,at least either the conductor side portions of the first segmentconductor or the conductor side portions of the second segment conductorin the slots such that the facing surface of one of the joint portionsof the first segment conductor and the facing surface of one of thejoint portions of the second segment conductor face each other;regulating movement of the conductor side portions in the radialdirection; and joining the joint portion of the first segment conductorand the joint portion of the second segment conductor to each other bypressing at least one of the first segment conductor and the secondsegment conductor in the axial direction such that the first segmentconductor and the second segment conductor approach each other whilemaintaining a regulating state.

With this characteristic configuration, movement of the conductor sideportions of the segment conductors in the radial direction is regulated.Therefore, displacement and separation of the joint portions of thefirst segment conductor and the joint portions of the second segmentconductor from each other in the radial direction can be restricted whensuch joint portions are to be joined to each other by pressing the firstsegment conductor and the second segment conductor in the axialdirection. Thus, the segment conductors can be easily joined to eachother appropriately.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view, taken along the radial direction, of a partof a rotary electric machine armature according to a first embodiment.

FIG. 2 is a sectional view, taken along the axial direction, of a partof the rotary electric machine armature according to the firstembodiment.

FIG. 3 illustrates a pair of segment conductors.

FIG. 4 is a sectional view, taken along the axial direction, of a partof a rotary electric machine armature according to a second embodiment.

FIG. 5 is a flowchart illustrating a method of manufacturing the rotaryelectric machine armature according to a first reference form.

FIG. 6 illustrates an arrangement process.

FIG. 7 illustrates a pressing process.

FIG. 8 illustrates a regulation process of a method of manufacturing arotary electric machine armature according to a third embodiment.

FIG. 9 is a flowchart illustrating the method of manufacturing therotary electric machine armature according to the third embodiment.

FIG. 10 illustrates a regulation process of the method of manufacturingthe rotary electric machine armature according to the third embodiment.

FIG. 11 illustrates a regulation process of a method of manufacturing arotary electric machine armature according to a fourth embodiment.

FIG. 12 illustrates a regulation process of a method of manufacturing arotary electric machine armature according to a fifth embodiment.

FIG. 13 illustrates a regulation process of the method of manufacturingthe rotary electric machine armature according to the fifth embodiment.

FIG. 14 illustrates a regulation process of a method of manufacturing arotary electric machine armature according to a sixth embodiment.

FIG. 15 is a flowchart illustrating a method of manufacturing a rotaryelectric machine armature according to a seventh embodiment.

FIG. 16 illustrates an insertion process according to the seventhembodiment.

FIG. 17 illustrates a regulation surface moving process.

FIG. 18 illustrates an insertion process according to a second referenceform.

FIG. 19 is a sectional view, taken along the radial direction, of a partof a rotary electric machine armature according to another embodiment.

FIG. 20 is a sectional view, taken along the radial direction, of a partof a rotary electric machine armature according to still anotherembodiment.

FIG. 21 illustrates joint portions of segment conductors shaped to befitted with each other in the radial direction.

FIG. 22 illustrates joint portions of segment conductors shaped to befitted with each other in the axial direction.

FIG. 23 illustrates one of a pair of segment conductors according to adifferent embodiment.

FIG. 24 illustrates the other of the pair of segment conductorsaccording to the different embodiment.

DETAILED DESCRIPTION OF EMBODIMENTS 1. First Embodiment

A rotary electric machine armature according to a first embodiment willbe described with reference to the drawings. Here, the rotary electricmachine armature is described as a stator 1 for a rotary electricmachine of an inner rotor type.

Herein, the term “rotary electric machine” refers to any of a motor(electric motor), a generator (electric generator), and a motorgenerator that functions both as a motor and as a generator asnecessary.

1-1. Overall Configuration of Stator

The overall configuration of the stator 1 according to the presentembodiment will be described below with reference to FIGS. 1 and 2. Asillustrated in FIGS. 1 and 2, the stator 1 includes a cylindrical statorcore 2 and a coil 3 wound around the stator core 2.

In the following description, unless otherwise noted, a “radialdirection R”, an “axial direction L”, and a “circumferential directionC” are defined with reference to a core reference surface S of thecylindrical stator core 2 to be discussed later. Further, a “radiallyinner side R1” indicates the inner side in the radial direction R of thecore reference surface S, and a “radially outer side R2” indicates theouter side in the radial direction R of the core reference surface S. Inaddition, a “first axial side L1” which is one side in the axialdirection L indicates the upper side in the axial direction L in FIG. 2,and a “second axial side L2” which is the other side in the axialdirection L indicates the lower side in the axial direction L in FIG. 2.

While a state in which the coil 3 is wound around the stator core 2 (seeFIGS. 1 and 2) is assumed in the following description, the terms“radial direction R”, “axial direction L”, and “circumferentialdirection C” are also used for the other states.

The stator core 2 is formed using a magnetic material, and functions asan “armature core”. In the present embodiment, the stator core 2 is alaminated structure in which a plurality of annular electrical steelplates are laminated on each other in the axial direction L. The statorcore 2 has a plurality of slots 21 that extend along the axial directionL and that are distributed in the circumferential direction C. Theplurality of slots 21 are disposed at constant intervals along thecircumferential direction C. A tooth 22 is formed between two slots 21that are adjacent to each other in the circumferential direction C.

Here, the “core reference surface” of the cylindrical stator core 2discussed above is an imaginary surface that serves as a reference forthe arrangement and the configuration of the slots 21. In the presentembodiment, as illustrated in FIG. 1, an imaginary cylindrical surface(core inner peripheral surface) including the end surfaces of aplurality of teeth 22 on the radially inner side R1 is defined as thecore reference surface S. The outer peripheral surface of the statorcore 2 may be defined as the core reference surface S.

The slots 21 are formed so as to penetrate the stator core 2 in theaxial direction L. In the present embodiment, the slots 21 are formed soas to extend in parallel with the axial direction L, and such that animaginary line (i.e. the center line in the width direction) that passesthrough the middle portion of each of the slots 21 in thecircumferential direction C extends in parallel with the radialdirection R. The slots 21 have respective radially opening portions 21 athat open in the radial direction R. In the present embodiment, theradially opening portions 21 a open toward the radially inner side R1.

Although not illustrated, a rotor that includes permanent magnets orelectromagnets to serve as a field is disposed on the radially innerside R1 of the stator 1 (stator core 2) so as to be rotatable relativeto the stator 1, and rotated by a rotating magnetic field generated fromthe stator 1. That is, the stator 1 according to the present embodimentis a stator for a rotary electric machine of an inner rotor type and ofa rotating field type.

1-2. Configuration of Coil

The configuration of the coil 3 will be described in detail below withreference to FIGS. 1 to 3. As illustrated in FIGS. 1 and 2, the coil 3has an n-layer wound structure in which n conductor side portions 41 tobe discussed later are arranged in the radial direction R. Here, n is aninteger of two or more (e.g. an integer of two or more and ten or less;particularly preferably an even number of two or more), and is set inaccordance with the magnitude of torque required from the rotaryelectric machine, an allowable counter-electromotive force, etc. In thepresent embodiment, the coil 3 has an eight-layer wound structure. Inaddition, the coil 3 has a structure in which at least one conductorside portion 41 is disposed in the circumferential direction C in eachof the slots 21. In the present embodiment, one conductor side portion41 is disposed in the circumferential direction C. That is, in thepresent embodiment, eight conductor side portions 41 are disposed in arow in each of the slots 21 so as to be stacked on each other in theradial direction R. Although not illustrated, a sheet-like insulatingmember is interposed between the coil 3 and the inner wall surfaces ofthe slots 21 in order to secure electrical insulation between the coil 3and the stator core 2.

The coil 3 is formed by successively joining a plurality of segmentconductors 4 to each other. The segment conductors 4 are constituted ofa linear conductor with a rectangular cross-sectional shape, forexample, taken along a plane that is orthogonal to the extensiondirection. The corner portions of the rectangular cross section of thelinear conductor are preferably formed to be beveled, rounded, orotherwise chamfered as appropriate. Examples of a material thatconstitutes the linear conductor include copper and aluminum. Inaddition, the surface of the linear conductor is coated with aninsulating film made of a resin etc. (such as polyimide, for example)except at portions (such as portions at which joint portions 43 to bediscussed later are formed) for electrical connection with a differentmember.

Here, the configuration of the segment conductors 4 will be describedwith reference to FIG. 3. FIG. 3 illustrates a pair of segmentconductors 4 joined to each other as viewed in the radial direction R,the axial direction L, and the circumferential direction C. The pair ofsegment conductors 4 as viewed in the radial direction R, the axialdirection L, and the circumferential direction C are illustrated in thelower left, upper, and right portions, respectively, in FIG. 3.

In the following description, the segment conductor 4, a crossoverportion 42 of which is disposed on the first axial side L1 with respectto the stator core 2, is defined as a first segment conductor 5, and thesegment conductor 4, a crossover portion 42 of which is disposed on thesecond axial side L2 with respect to the stator core 2, is defined as asecond segment conductor 6. In the case where the term “segmentconductors 4” is used, both the first segment conductor 5 and the secondsegment conductor 6 are meant without distinction.

As illustrated in FIG. 3, the segment conductors 4 are formed in aU-shape as viewed in the radial direction R. The segment conductors 4each have a pair of conductor side portions 41 and a crossover portion42 that connects between the pair of conductor side portions 41. In thepresent embodiment, the pair of conductor side portions 41 havedifferent lengths in the axial direction L. Therefore, in the followingdescription, one of the pair of conductor side portions 41 that islonger in the axial direction L than the other is defined as a firstconductor side portion 411, and the conductor side portion 41 that isshorter in the axial direction L than the first conductor side portion411 is defined as a second conductor side portion 412. In the case wherethe term “conductor side portions 41” is used, both the first conductorside portion 411 and the second conductor side portion 412 are meantwithout distinction.

The conductor side portions 41 extend in the axial direction L inparallel with the slots 21. Joint portions 43 to be joined to differentconductor side portions 41 are formed at the distal end portions of theconductor side portions 41, that is, the end portions thereof on theopposite side from the portions of connection with the crossover portion42. The configuration of the joint portions 43 will be discussed indetail later.

The crossover portion 42 connects between the pair of conductor sideportions 41. In the present embodiment, the crossover portion 42 of thefirst segment conductor 5 connects between the end portions, on thefirst axial side L1, of the pair of conductor side portions 41 of thefirst segment conductor 5, and the crossover portion 42 of the secondsegment conductor 6 connects between the end portions, on the secondaxial side L2, of the pair of conductor side portions 41 of the secondsegment conductor 6. That is, the crossover portion 42 is connected tothe conductor side portions 41. In addition, the crossover portion 42extends in the circumferential direction C. An offset portion 421 thatoffsets the pair of conductor side portions 41 in the radial direction Ris formed at the crossover portion 42. In the present embodiment, theoffset portion 421 is formed at the middle portion of the crossoverportion 42 in the circumferential direction C, and formed so as tooffset the pair of conductor side portions 41 in the radial direction

R by one layer. With the presence of the offset portion 421, the pair ofconductor side portions 41 of the segment conductor 4 are adjacent toeach other without overlapping each other as viewed in thecircumferential direction C.

Here, when two members are described as being disposed to “overlap” eachother, it is indicated that, when an imaginary line that is parallel tothe viewing direction is moved in directions that are orthogonal to theimaginary line, there is a region in which the imaginary line crossesboth of the two members.

In the present embodiment, the coil 3 is wound around the stator core 2by lap winding. Therefore, as illustrated in FIG. 3, in the case whereone first segment conductor 5 and one second segment conductor 6 areextracted, the joint portion 43 of the first conductor side portion 411of the first segment conductor 5 and the joint portion 43 of the secondconductor side portion 412 of the second segment conductor 6 are joinedto each other. The second conductor side portion 412 of the firstsegment conductor 5 and the first conductor side portion 411 of thesecond segment conductor 6 are disposed at the same position in thecircumferential direction C, and disposed at different positions in theradial direction R. In addition, the joint portion 43 of the secondconductor side portion 412 of the first segment conductor 5 and thejoint portion 43 of the first conductor side portion 411 of a differentsecond segment conductor 6 (not illustrated) are joined to each other.Similarly, the joint portion 43 of the first conductor side portion 411of the second segment conductor 6 and the joint portion 43 of the secondconductor side portion 412 of a different first segment conductor 5 (notillustrated) are joined to each other.

In the present embodiment, as illustrated in FIG. 2, the conductor sideportions 41 are disposed in the slot 21, and the crossover portions 42are disposed on the outer sides of the stator core 2 in the axialdirection L. In the present embodiment, the joint portions 43 of thefirst segment conductors 5 and the joint portions 43 of the secondsegment conductors 6 are joined to each other in the slot 21.

The joint portions 43 have respective facing surfaces 44. The facingsurfaces 44 of the pair of joint portions 43 which are joined to eachother are formed so as to face each other. The joint portions 43 and thefacing surfaces 44 are formed such that, with the pair of facingsurfaces 44 facing each other and with the joint portions 43 joined toeach other, the pair of conductor side portions 41 (the first conductorside portion 411 and the second conductor side portion 412) in which thejoint portions 43 are formed extend straight along the axial directionL.

The facing surface 44 is formed so as not to have portions that overlapeach other as viewed in the radial direction R over the entire facingsurface 44. In the present embodiment, the facing surfaces 44 are formedover the entire axial end surfaces of the distal end portions of theconductor side portions 41, and are flat surfaces that extend in adirection inclined with respect to the axial direction L. In addition,one of the facing surfaces 44 which face each other is constituted ofonly a surface that faces one side in the radial direction R, and theother of the facing surfaces 44 which face each other is constituted ofonly a surface that faces the other side in the radial direction R. Inthe present embodiment, the facing surface 44 of the first conductorside portion 411 is constituted of only a surface that faces theradially inner side R1, and the facing surface 44 of the secondconductor side portion 412 is constituted of only a surface that facesthe radially outer side R2. Here, the wording “the facing surface 44 isconstituted of only a surface that faces one side in the radialdirection R” means that the facing surface 44 does not include a surfacethat faces the other side in the radial direction R. The wording“surface that faces the other side in the radial direction R” refers toa surface, the normal vector of which has a component toward the otherside in the radial direction R. In addition, the wording “the facingsurface 44 is constituted of only a surface that faces the other side inthe radial direction R” means that the facing surface 44 does notinclude a surface that faces one side in the radial direction R. Thewording “surface that faces one side in the radial direction R” refersto a surface, the normal vector of which has a component toward one sidein the radial direction R.

The facing surface 44 is also formed so as not to have portions thatoverlap each other as viewed in the circumferential direction C over theentire facing surface 44. In the present embodiment, the facing surfaces44 are disposed in parallel with the circumferential direction C. Inaddition, the facing surfaces 44 are formed so as not to have a portionprojecting or dented in the axial direction L in the facing surfaces 44.Here, the wording “the facing surfaces 44 do not have a portionprojecting or dented in the axial direction L” means that the facingsurfaces 44 do not have a projection or a recess in the axial directionL, and the facing surfaces 44 may be formed with a projection or arecess in the radial direction R or the circumferential direction C.

Meanwhile, a projection or a recess in the axial direction L may beformed by portions other than the facing surfaces 44 or by the facingsurface 44 and a portion other than the facing surface 44. The “facingsurfaces 44 have a portion projecting or dented in the axial directionL” in the case where the inclination directions of portions of thefacing surfaces 44 are opposite to each other in the axial direction L,such as a case where the inclination direction of a part of the facingsurface 44 is a direction toward one side in the axial direction and theinclination direction of another part of the facing surface 44 is adirection toward the other side in the axial direction.

Each of the facing surfaces 44 is shaped to match the shape of the otherof the facing surfaces 44 which face each other. In the presentembodiment, the facing surfaces 44 which face each other have the sameshape as each other, and are disposed in parallel with each other.

With the facing surfaces 44 configured as described above, the pair ofsegment conductors 4 can receive a load in the radial direction R withthe entire facing surfaces 44 of the joint portions 43 which are joinedto each other. In Japanese Patent Application Publication No.2015-023771 discussed above, on the other hand, projecting portions(projecting portions 60) are formed at the distal end portions ofconductor side portions (first-side leg portions 32 and 33) of the firstsegment conductors (first-side conductor segments 28), and recessedportions (recessed portions 62) are formed at the distal end portions ofconductor side portions (second-side leg portions 40 and 41) of thesecond segment conductors (second-side conductor segments 29 and 30).Therefore, the first segment conductors (first-side conductor segments28) and the second segment conductors (second-side conductor segments 29and 30) can receive a load in the radial direction with only arelatively small range of the facing surfaces.

2. Second Embodiment

A rotary electric machine armature according to a second embodiment willbe described below with reference to FIG. 4. In the present embodiment,the configuration of the facing surfaces 44 of the joint portions 43 ofthe segment conductors 4 is different from that according to the firstembodiment described above. The differences from the first embodimentdescribed above will be mainly described below. The same elements asthose in the first embodiment described above will not be particularlydescribed.

In the present embodiment, as illustrated in FIG. 4, the facing surfaces44 are formed over the entire axial end surfaces of the distal endportions of the conductor side portions 41, and each include a firstinclined surface 441, a second inclined surface 442, and a thirdinclined surface 443. The first inclined surface 441, the secondinclined surface 442, and the third inclined surface 443 are disposed inthis order from the distal end portion toward the base end portion ofthe conductor side portion 41 in the axial direction L. In the presentembodiment, the facing surfaces 44 which face each other have the sameshape as each other, and are disposed in parallel with each other. Inthe present example, in addition, all of the first inclined surface 441,the second inclined surface 442, and the third inclined surface 443 aredisposed in parallel with the circumferential direction C.

The first inclined surface 441 is formed so as to extend along adirection inclined with respect to the axial direction L. In the presentembodiment, the first inclined surface 441 is a flat surface formed toinclude the tip portion of the conductor side portion 41 and extendingin a direction inclined with respect to the axial direction L.

The second inclined surface 442 is formed so as to extend along adirection that intersects the direction in which the first inclinedsurface 441 extends. In the present embodiment, the second inclinedsurface 442 is disposed between the first inclined surface 441 and thethird inclined surface 443 in the axial direction L. The second inclinedsurface 442 is formed to be continuous with the first inclined surface441, and forms a projecting portion projecting in the radial direction Rtogether with the first inclined surface 441. Therefore, the secondinclined surface 442 is a flat surface that extends in a directioninclined with respect to the axial direction L in a different directionfrom the first inclined surface 441. In addition, the second inclinedsurface 442 is formed so as to overlap the first inclined surface 441 asviewed in the axial direction L. In the present embodiment, the entiresecond inclined surface 442 overlaps the first inclined surface 441 asviewed in the axial direction L. In the present example, the firstinclined surface 441 and the second inclined surface 442 are smoothlycontinuous with each other via a curved portion. However, the presentdisclosure is not limited thereto. It is also suitable if the firstinclined surface 441 and the second inclined surface 442 are continuousby intersecting each other via an angled portion.

The third inclined surface 443 is formed so as to extend along adirection that intersects the direction in which the second inclinedsurface 442 extends. In the present embodiment, the third inclinedsurface 443 is disposed on the side of the base end portion with respectto the second inclined surface 442 in the axial direction L. The thirdinclined surface 443 is formed to be continuous with the second inclinedsurface 442, and forms a recessed portion dented in the radial directionR together with the second inclined surface 442. Therefore, the thirdinclined surface 443 is a flat surface that extends in a directioninclined with respect to the axial direction L in a different directionfrom the second inclined surface 442. Specifically, the third inclinedsurface 443 is a flat surface that extends in a direction that isparallel to the first inclined surface 441. Further, the length of thethird inclined surface 443 in the extension direction is the same as thelength of the first inclined surface 441 in the extension direction. Inthe present embodiment, the second inclined surface 442 and the thirdinclined surface 443 are smoothly continuous with each other via acurved portion. However, the present disclosure is not limited thereto.It is also suitable if the second inclined surface 442 and the thirdinclined surface 443 are continuous by intersecting each other via anangled portion.

In the present embodiment, with the pair of conductor side portions 41joined to each other, the first inclined surface 441 of the firstconductor side portion 411 and the third inclined surface 443 of thesecond conductor side portion 412 face each other, the second inclinedsurface 442 of the first conductor side portion 411 and the secondinclined surface 442 of the second conductor side portion 412 face eachother, and the third inclined surface 443 of the first conductor sideportion 411 and the first inclined surface 441 of the second conductorside portion 412 face each other.

In the present embodiment, as described above, the facing surface 44 isformed so as not to have portions that overlap each other as viewed inthe radial direction R and the circumferential direction C over theentire facing surface 44. In the present embodiment, in addition, thefacing surface 44 of the first conductor side portion 411 is constitutedof only a surface that faces the radially inner side R1, and the facingsurface 44 of the second conductor side portion 412 is constituted ofonly a surface that faces the radially outer side R2. In the presentembodiment, in addition, the facing surfaces 44 are formed so as not tohave a portion projecting or dented in the axial direction L in thefacing surfaces 44.

3. First Reference Form of Method of Manufacturing Rotary ElectricMachine Armature

A manufacturing process S1 for the stator 1, which is a first referenceform of a method of manufacturing a rotary electric machine armature,will be described below with reference to FIGS. 5 to 7. The stator 1according to the second embodiment described above (see FIG. 4) ismanufactured in the manufacturing process S1 according to the presentreference form.

As illustrated in FIG. 5, the manufacturing process S1 according to thepresent reference form includes a preparation process S10, a jointmaterial arrangement process S11, an arrangement process S12, a pressingprocess S13, and a joint process S14.

In the preparation process S10, a plurality of segment conductors 4 thatconstitute a coil 3 and a stator core 2 are prepared. In the preparationprocess S10, a plurality of first segment conductors 5 and secondsegment conductors 6, the number of the second segment conductorscorresponding to the number of the first segment conductors 5, areprepared as the segment conductors 4.

In the joint material arrangement process S11, a conductive jointmaterial 8 is disposed on at least one of the facing surfaces 44 whichface each other. As illustrated in FIG. 6, the conductive joint material8 is a joint material that joins the joint portions 43 of the firstsegment conductor 5 and the joint portions 43 of the second segmentconductor 6 to each other while securing conductivity. Examples of theconductive joint material 8 include a paste-like joint materialcontaining silver nanoparticles.

In the arrangement process S12, at least either the conductor sideportions 41 of the first segment conductor 5 and the conductor sideportions 41 of the second segment conductor 6 are disposed in the slots21 such that the facing surface 44 of one of the joint portions 43 ofthe first segment conductor 5 and the facing surface 44 of one of thejoint portions 43 of the second segment conductor 6 face each other. Inthe arrangement process S12 according to the present embodiment, asillustrated in FIG. 6, the plurality of first segment conductors 5 andthe plurality of second segment conductors 6 are disposed in theplurality of slots 21 such that the facing surface 44 of the firstconductor side portion 411 of the first segment conductor 5 and thefacing surface 44 of the second conductor side portion 412 of the secondsegment conductor 6 face each other and the facing surface 44 of thesecond conductor side portion 412 of the first segment conductor 5 andthe facing surface 44 of the first conductor side portion 411 of adifferent second segment conductor 6 face each other in each of theslots 21.

In the pressing process S13, at least a part of the pair of conductorside portions 41, which are to be joined to each other, of the pluralityof segment conductors 4 is pressed in the radial direction R. In thepressing process S13 according to the present reference form, portionsof the plurality of segment conductors 4 at which the pair of jointportions 43 to be joined to each other overlap each other as viewed inthe radial direction R are pressed from the radially opening portion 21a. In other words, in the pressing process S13, a region in which thepair of facing surfaces 44 of the pair of joint portions 43 to be joinedface each other as viewed in the radial direction R is pressed from theradially opening portion 21 a. In the present reference form, asillustrated in FIG. 7, the pressing process S13 is performed using apressing device 9. The pressing device 9 includes a fixed member 91, aplurality of movable members 92, and an insertion member 93.

The fixed member 91 is formed in a cylindrical shape, and has an outsidediameter that enables the fixed member 91 to be disposed on the radiallyinner side R1 with respect to the plurality of segment conductors 4which are disposed in the slots 21. The fixed member 91 is disposed onthe radially inner side R1 with respect to the core inner peripheralsurface (core reference surface S) in the stator core 2 so as to becoaxial with the stator core 2, and fixed to the stator core 2. Thefixed member 91 has an outer peripheral surface 91 a that extends alongthe axial direction L over the entire region in the circumferentialdirection C, and a bottom surface 91 b that extends from an end portionof the outer peripheral surface 91 a on the second axial side L2 towardthe radially outer side R2. In the present reference form, the outerperipheral surface 91 a of the fixed member 91 is formed in acylindrical shape, and the bottom surface 91 b is formed in a circularplate shape.

The pressing device 9 includes movable members 92, the number of themovable members 92 being the same as that of the slots 21 of the statorcore 2. The movable members 92 are each formed in a plate shape. All themovable members 92 are disposed radially with reference to the axis ofthe stator core 2 in correspondence with the slots 21 of the stator core2. In addition, the movable members 92 are inserted into the respectiveslots 21 from the respective radially opening portions 21 a of the slots21. In this event, the movable members 92 are each disposed such that apart of the movable member 92 on the radially inner side R1 projectstoward the radially inner side R1 with respect to the radially openingportion 21 a of the slot 21. In addition, the movable members 92 areplaced on the bottom surface 91 b of the fixed member 91. Further, themovable member 92 has an inner peripheral-side inclined surface 92 a.The inner peripheral-side inclined surface 92 a is an inclined surfaceformed on the radially inner side R1 of the movable member 92 to extendtoward the radially inner side R1 from the first axial side L1 towardthe second axial side L2.

The movable member 92 also has a first pressing portion 921 and a secondpressing portion 922. The first pressing portion 921 and the secondpressing portion 922 are formed on a surface of the movable member 92 onthe radially outer side R2. The first pressing portion 921 is formed soas to project toward the radially outer side R2 with respect to portionson both sides in the axial direction L, and disposed in accordance withthe position, in the axial direction L, of a portion at which the jointportion 43 of the second conductor side portion 412 of the first segmentconductor 5 and the joint portion 43 of the first conductor side portion411 of the second segment conductor 6 overlap each other as viewed inthe radial direction R. The second pressing portion 922 is formed so asto project toward the radially outer side R2 with respect to portions onboth sides in the axial direction L, and disposed in accordance with theposition, in the axial direction L, of a portion at which the jointportion 43 of the first conductor side portion 411 of the first segmentconductor 5 and the joint portion 43 of the second conductor sideportion 412 of the second segment conductor 6 overlap each other asviewed in the radial direction R. In the present reference form,respective portions of the first pressing portion 921 and the secondpressing portion 922 that project most toward the radially outer side R2are each shaped as a flat surface that is parallel to the axialdirection L.

The insertion member 93 is formed in a cylindrical shape, and insertedinto a space in the radial direction R between the fixed member 91 andthe movable members 92. The insertion member 93 has an inner peripheralsurface 93 a and an outer peripheral-side inclined surface 93 b. Theinner peripheral surface 93 a of the insertion member 93 is formed alongthe outer peripheral surface 91 a of the fixed member 91. Here, theinner peripheral surface 93 a is a cylindrical surface that has aninside diameter that is slightly larger than the diameter of the outerperipheral surface 91 a of the fixed member 91. Meanwhile, the outerperipheral-side inclined surface 93 b of the insertion member 93 is atruncated cone surface formed such that the inclination angle thereofwith respect to the axial direction L is the same as the angle of theinner peripheral-side inclined surfaces 92 a of the movable members 92.In addition, the thickness of the insertion member 93 in the radialdirection R is set such that the lower end portion of the insertionmember 93 which contacts the inner peripheral-side inclined surfaces 92a of the movable members 92 does not abut against the bottom surface 91b of the fixed member 91 with the movable members 92 moved most to theradially outer side R2 within the movable range thereof.

In the pressing process S13, the movable members 92 are moved toward theradially outer side R2 along the bottom surface 91 b of the fixed member91 by inserting the insertion member 93 from the first axial side L1into a space in the radial direction R between the fixed member 91 andthe plurality of movable members 92 which are disposed radially.Consequently, the first pressing portion 921 and the second pressingportion 922 of the movable member 92 press the segment conductor 4 inthe slot 21 from the radially inner side R1 (i.e. from the radiallyopening portion 21 a of the slot 21). In this way, in the pressingprocess S13 according to the present reference form, the joint portions43 of the segment conductors 4 in all the slots 21 can be pressed usingthe pressing device 9. In this event, the pair of conductor sideportions 41 to be joined to each other are disposed straight along theaxial direction L, and therefore a pressing force applied by the firstpressing portion 921 and a pressing force applied by the second pressingportion 922 are unlikely to be non-uniform.

In the present reference form, when the segment conductor 4 is pressedby the movable member 92, the movable member 92 is moved toward theradially outer side R2 such that the pressing force of the movablemember 92 is transferred to an inner wall surface 21 b of the slot 21 onthe opposite side (radially outer side R2) from the side of the radiallyopening portion 21 a. In this way, the joint portions 43 of all thesegment conductors 4 in each of the slots 21 are pressed in the state ofbeing interposed between the movable member 92 and the inner wallsurface 21 b of the slot 21 on the opposite side (radially outer sideR2) from the side of the radially opening portion 21 a.

In the pressing process S13 according to the present reference form, asillustrated in FIG. 7, a pressing region PA of the conductor sideportions 41 of the plurality of segment conductors 4 which are disposedin the slot 21, including the joint portions 43 of the first segmentconductors 5 and the joint portions 43 of the second segment conductors6, is pressed by the first pressing portion 921 and the second pressingportion 922. On the other hand, a non-pressing region NA of theconductor side portions 41 of the plurality of segment conductors 4which are disposed in the slot 21, excluding the pressing region PA, isnot pressed.

In the present reference form, the joint portion 43 of the secondconductor side portion 412 of the first segment conductor 5 and thejoint portion 43 of the first conductor side portion 411 of the secondsegment conductor 6 are joined to each other, and the joint portion 43of the first conductor side portion 411 of the first segment conductor 5and the joint portion 43 of the second conductor side portion 412 of thesecond segment conductor 6 are joined to each other. Therefore, aportion of the plurality of segment conductors 4 disposed in the slot 21at which the pair of joint portions 43 to be joined to each otheroverlap each other as viewed in the radial direction R is positioned attwo locations in the axial direction L. Hence, in the present referenceform, the pressing region PA is positioned at two locations, in theaxial direction L, of the plurality of segment conductors 4 which aredisposed in the slot 21. The present disclosure is not limited thereto.A portion at which the pair of joint portions 43 to be joined to eachother overlap each other as viewed in the radial direction R may bepositioned at one or three or more locations, in the axial direction L,of the plurality of segment conductors 4 which are disposed in the slot21. That is, the pressing region PA may be positioned at one or three ormore locations, in the axial direction L, of the plurality of segmentconductors 4 which are disposed in the slot 21.

In the joint process S14, the joint portion 43 of the first segmentconductor 5 and the joint portion 43 of the second segment conductor 6are joined to each other while maintaining the pressing state in thepressing process S13 discussed above. In the present reference form, thepaste-like joint material containing silver nanoparticles discussedabove is adopted as the conductive joint material 8. Therefore, in thejoint process S14, the joint portion 43 of the first segment conductor 5and the joint portion 43 of the second segment conductor 6 are joined toeach other by heating and melting the conductive joint material 8 usinga heater etc., for example.

4. Third Embodiment

A rotary electric machine armature according to a third embodiment willbe described below with reference to FIG. 8. In the present embodiment,the configuration of the facing surfaces 44 of the joint portions 43 ofthe segment conductors 4 is different from that according to the firstembodiment described above and the second embodiment described above.The differences from the first embodiment described above and the secondembodiment described above will be mainly described below. The sameelements as those in the first embodiment described above and the secondembodiment described above will not be particularly described.

In the present embodiment, as illustrated in FIG. 8, the facing surfaces44 are formed over the entire axial end surfaces of the distal endportions of the conductor side portions 41, and are flat surfaces thatextend along the radial direction R. In the present embodiment, thefacing surfaces 44 are disposed in parallel with the circumferentialdirection C. In the present embodiment, in addition, the facing surfaces44 which face each other have the same shape as each other, and aredisposed in parallel with each other.

As illustrated in FIG. 9, the manufacturing process S1 for the stator 1according to the present embodiment includes a regulation process S15 inplace of the pressing process S13 discussed above. In the regulationprocess S15, movement of the conductor side portions 41 in the radialdirection R is regulated. In the regulation process S15 according to thepresent embodiment, movement of the joint portions 43 in the radialdirection R in the slot 21 is regulated. The pressing process S13discussed above is one form of the regulation process S15. In thepresent embodiment, as illustrated in FIG. 8, the regulation process S15is performed using a regulation member 10.

The regulation member 10 is disposed on the side of the radially openingportion 21 a (radially inner side R1) with respect to the conductor sideportions 41 positioned most on the side of the radially opening portion21 a (radially inner side R1) in the slot 21. In the present embodiment,the regulation member 10 is inserted into the slot 21 through theradially opening portion 21 a. That is, the width of the regulationmember 10 in the circumferential direction C is smaller than the widthof the radially opening portion 21 a in the circumferential direction C.

The regulation member 10 has a regulation surface 11 that faces theconductor side portions 41 of the segment conductors 4 which aredisposed in the slot 21. The regulation surface 11 regulates movement,in the radial direction R, of the conductor side portions 41 of thesegment conductors 4 which are disposed in the slot 21. The regulationsurface 11 is formed so as to face an object region OA which is theentire region or a part of the region, in the axial direction L, of boththe conductor side portions 41 of the first segment conductors 5 and theconductor side portions 41 of the second segment conductors 6. In thepresent embodiment, the object region OA is the entire region, in theaxial direction L, of both the conductor side portions 41 of the firstsegment conductors 5 and the conductor side portions 41 of the secondsegment conductors 6. In addition, the regulation surface 11 is shapedalong a surface that faces the regulation surface 11 in the objectregion OA. Specifically, in the present embodiment, the regulationsurface 11 is shaped along the side surfaces of the conductor sideportions 41 in the radial direction R. That is, in the presentembodiment, the regulation surface 11 is a flat surface that extendsalong the axial direction L, and formed in parallel with thecircumferential direction C.

In the regulation process S15, the regulation member 10 is disposed onthe side of the radially opening portion 21 a (radially inner side R1)with respect to the pair of conductor side portions 41 positioned moston the side of the radially opening portion 21 a (radially inner sideR1) in the slot 21. Then, the regulation member 10 is disposed such thatthe regulation surface 11 extends along the pair of conductor sideportions 41 positioned most on the side of the radially opening portion21 a (radially inner side R1). In the present example, the regulationmember 10 causes the regulation surface 11 to contact the pair ofconductor side portions 41 so as not to press the pair of conductor sideportions 41. At this time, it is suitable if the pair of conductor sideportions 41 positioned most on the opposite side (radially outer sideR2) from the side of the radially opening portion 21 a contact the innerwall surface 21 b of the slot 21 on the radially outer side R2, and if aplurality of pairs of conductor side portions 41 arranged in the radialdirection R in the slot 21 contact each other. However, there may be agap therebetween.

In the joint process S14 according to the present embodiment, at leasteither the first segment conductors 5 or the second segment conductors 6are pressed in the axial direction L such that the first segmentconductors 5 and the second segment conductors 6 approach each otherwhile maintaining the regulating state in the regulation process S15. Inthe present example, the plurality of segment conductors 4 which aredisposed in the slot 21 are pressed from both sides in the axialdirection L (the first axial side L1 and the second axial side L2) whilemaintaining the regulating state in the regulation process S15. At thistime, movement in the radial direction R of the plurality of pairs ofconductor side portions 41 which are arranged in the radial direction Rin the slot 21 is regulated between the regulation surface 11 of theregulation member 10 and the inner wall surface 21 b of the slot 21 onthe radially outer side R2. Therefore, even in the case where theplurality of segment conductors 4 are pressed from both sides in theaxial direction L, the pair of joint portions 43 which face each otherare not displaced or separated from each other in the radial direction.

In the joint process S14 according to the present embodiment, theregulation surface 11 is fixed in position in the radial direction R. Inthe present example, the regulation surface 11 is formed on the endsurface of the regulation member 10 on the radially outer side R2, andtherefore the regulation surface 11 is fixed in position in the radialdirection R by fixing the regulation member 10 in position in the radialdirection R.

It is not necessary to cause the regulation surface 11 of the regulationmember 10 to contact the pair of conductor side portions 41 positionedmost on the side of the radially opening portion 21 a (radially innerside R1) before the plurality of segment conductors 4 are pressed in theaxial direction L as long as movement of the conductor side portions 41in the radial direction R can be regulated. The regulation member 10 isnot limited to the configuration described above. For example, theregulation member 10 may be configured to be shaped similarly to thesurface shape, on the radially outer side R2, of the movable member 92which has the first pressing portion 921 and the second pressing portion922 and which is used in the pressing process S13 described above. Inthis case, the end surface, on the radially outer side R2, of a portioncorresponding to the first pressing portion 921 and the end portion, onthe radially outer side R2, of a portion corresponding to the secondpressing portion 922 function as the regulation surface 11. That is, inthis case, the regulation surface 11 faces both the joint portion 43 ofthe first segment conductor 5 and the joint portion 43 of the secondsegment conductor 6.

Alternatively, the regulation surface 11 may be shaped as illustrated inFIG. 10, for example. In the example illustrated in FIG. 10, the objectregion OA is a part of the region, in the axial direction L, of both theconductor side portions 41 of the first segment conductors 5 and theconductor side portions 41 of the second segment conductors 6.Specifically, in the example illustrated in FIG. 10, the object regionOA is portions of the conductor side portions 41 of the plurality ofsegment conductors 4 disposed in the slot 21 excluding portions at whichthe pair of joint portions 43 to be joined to each other overlap eachother as viewed in the radial direction R. Therefore, in the exampleillustrated in FIG. 10, the regulation surface 11 is formed at threelocations in the axial direction L so as to face portions of theconductor side portions 41 of the plurality of segment conductors 4disposed in the slot 21 at which the pair of joint portions 43 to bejoined to each other do not overlap each other as viewed in the radialdirection R.

The segment conductors 4 may be pressed by a portion of the movablemember 92 corresponding to the regulation surface 11 by applying theshape of the surface, on the radially outer side R2, of the regulationmember 10 which includes the regulation surface 11 to the shape of thesurface, on the radially outer side R2, of the movable member 92 whichis used in the pressing process S13 described above. In the case wherethe shape of a portion of the movable member 92 corresponding to theregulation surface 11 is similar to the shape of the regulation surface11 illustrated in FIG. 8, the entire region of the conductor sideportions 41 in the axial direction L is pressed, and therefore a uniformpressing force can be applied to the conductor side portions 41. In thecase where the shape of a portion of the movable member 92 correspondingto the regulation surface 11 is similar to the shape of the regulationsurface 11 illustrated in FIG. 10, on the other hand, the conductivejoint material 8 which is disposed between the joint portion 43 of thefirst segment conductor 5 and the joint portion 43 of the second segmentconductor 6 is unlikely to adhere to a portion of the movable member 92corresponding to the regulation surface 11.

In addition, it is also suitable if the method of manufacturing thestator 1 which includes the regulation process S15 in place of thepressing process S13 as in the present embodiment is performed using thesegment conductors 4 which have the facing surfaces 44 which areconfigured as described above in relation to the first embodiment or thesecond embodiment.

5. Fourth Embodiment

A rotary electric machine armature according to a fourth embodiment willbe described below with reference to FIG. 11. In the present embodiment,the configuration of the slots 21 of the stator core 2 is different fromthat according to the first embodiment described above and the secondembodiment described above. The differences from the first embodimentdescribed above and the second embodiment described above will be mainlydescribed below. The same elements as those in the first embodimentdescribed above and the second embodiment described above will not beparticularly described.

In the present embodiment, as illustrated in FIG. 11, the slots 21 aresemi-open slots. Specifically, the width of the radially opening portion21 a in the circumferential direction C is smaller than the width, inthe circumferential direction C, of a region of the slot 21 in which theconductor side portions 41 are disposed. In other words, projectingportions that project toward both sides in the circumferential directionC are formed at distal end portions 22 a of the teeth 22.

A sheet-like insulating member 7 is provided in each of the slots 21 inorder to secure electrical insulation between the coil 3 and the statorcore 2. Specifically, the insulating member 7 is interposed between theconductor side portions 41 and the inner wall surface of the slot 21.

In the following, for convenience of description, all of the conductorside portions 41 in each of the slots 21 will be referred to as a“conductor side portion group”.

In the present embodiment, the insulating member 7 is disposed so as tocover the side surfaces of the conductor side portion group on bothsides in the circumferential direction C (surfaces that face the innerwall surfaces of the slot 21 on both sides in the circumferentialdirection C) and the side surface of the conductor side portion group onthe radially outer side R2 (a surface that faces the inner wall surfaceof the slot 21 on the radially outer side R2). In other words, in thepresent embodiment, the insulating member 7 is disposed so as to coverall the side surfaces of the conductor side portion group excluding theside surface thereof on the side of the radially opening portion 21 a(radially inner side R1). In addition, the insulating member 7 is longerin the axial direction L than the slot 21, although not illustrated.Hence, the insulating member 7 is disposed so as to project in the axialdirection L from both end portions of the slot 21 in the axial directionL. Further, in the present example, as illustrated in FIG. 11, theinsulating member 7 has portions that extend toward the radially openingportion 21 a from portions that contact the side surfaces of theconductor side portion group on both sides in the circumferentialdirection C. Such portions are eventually folded to be disposed so as tocover the side surface of the conductor side portion group on the sideof the radially opening portion 21 a (radially inner side R1).

The manufacturing process S1 according to the reference form of themethod of manufacturing the stator 1 according to the present embodimentincludes the pressing process S13 discussed above. As illustrated inFIG. 11, the pressing process S13 of the manufacturing process S1according to the present reference form is performed using a pressingdevice 9 that includes a plurality of movable members 92, the width ofwhich in the circumferential direction C is smaller than that of theradially opening portions 21 a. The movable members 92 according to thepresent reference form are the same as those used in the pressingprocess S13 discussed above except for the width in the circumferentialdirection C. In the pressing process S13 according to the presentreference form, the movable members 92 are inserted into the radiallyopening portions 21 a from the radially inner side R1. Then, theconductor side portion groups are pressed by the movable members 92 fromthe radially opening portions 21 a toward the radially outer side R2.

The manufacturing process S1 for the stator 1 according to the presentembodiment includes a regulation process S15 in place of the pressingprocess S13. In the regulation process S15 according to the presentembodiment, for example, the movable member 92 described above, thewidth of which in the circumferential direction C is smaller than thatof the radially opening portion 21 a, is fixed at a position at whichthe movable member 92 contacts the conductor side portion group, ratherthan being moved toward the radially outer side R2. Then, the pluralityof segment conductors 4 which are disposed in the slot 21 are pressedfrom both sides in the axial direction L (the first axial side L1 andthe second axial side L2).

6. Fifth Embodiment

A fifth embodiment will be described below with reference to FIG. 12. Ina reference form of a method of manufacturing the stator 1 according tothe present embodiment, the configuration of the movable member 92 isdifferent from that according to the reference form of the method ofmanufacturing the stator 1 according to the fourth embodiment describedabove. The differences from the reference form of the method ofmanufacturing the stator 1 according to the fourth embodiment describedabove will be mainly described below. The same elements as those in thereference form of the method of manufacturing the stator 1 according tothe fourth embodiment described above will not be particularlydescribed.

As illustrated in FIG. 12, the pressing process S13 according to thepresent reference form is performed using a pressing device 9 thatincludes a plurality of movable members 92 that each have a narrowportion 92 b and a wide portion 92 c. The movable members 92 accordingto the present reference form each have the narrow portion 92 b and thewide portion 92 c. The movable members 92 are otherwise the same inconfiguration as those used in the pressing process S13 discussed above.The width of the narrow portion 92 b in the circumferential direction Cis smaller than the width of the radially opening portion 21 a in thecircumferential direction C. The width of the wide portion 92 c in thecircumferential direction C is larger than the width of the radiallyopening portion 21 a in the circumferential direction C, and smallerthan the width, in the circumferential direction C, of a region of theslot 21 in which the conductor side portions 41 are disposed. Inaddition, the length of the wide portion 92 c in the radial direction Ris less than the distance between the conductor side portion group andthe radially opening portion 21 a (the projecting portions which areformed at the distal end portions 22 a of the teeth 22 to project in thecircumferential direction C). The wide portion 92 c is disposed at anend portion of the narrow portion 92 b on the radially outer side R2.The wide portion 92 c has a shape that matches the space between theradially opening portion 21 a and the conductor side portion group inthe slot 21.

In the pressing process S13 according to the present reference form, themovable members 92 are inserted into the slots 21 along the axialdirection L such that the narrow portion 92 b is positioned in theradially opening portion 21 a and the wide portion 92 c is positioned inthe space between the radially opening portion 21 a and the conductorside portion group in the slot 21. Then, the conductor side portiongroups are pressed by the movable members 92 toward the radially outerside R2. In this event, in the present example, as illustrated in FIG.12, portions of the insulating member 7 positioned between the radiallyopening portion 21 a and the conductor side portion group extend alongportions of the inner wall surfaces of the slot 21 in thecircumferential direction C not faced by the conductor side portiongroup.

In the pressing process S13 according to the present reference form, asillustrated in FIG. 13, a pressing device 9 that includes a plurality ofinner pressing members 94 may be used in place of the pressing device 9which includes the plurality of movable members 92 discussed above. Theshape of a portion of the inner pressing member 94 to be inserted intothe slot 21 is similar to the shape of the movable member 92 discussedabove from which the narrow portion 92 b has been removed and whichincludes only the wide portion 92 c. The inner pressing member 94 islonger in the axial direction L than the stator core 2. The innerpressing member 94 is inserted into the space between the radiallyopening portion 21 a and the conductor side portion group in the slot 21along the axial direction L. Consequently, the inner pressing member 94is disposed such that both end portions thereof in the axial direction Lproject toward both sides in the axial direction L (the first axial sideL1 and the second axial side L2) from the stator core 2. The innerpressing member 94 is moved toward the radially outer side R2 with bothend portions of the inner pressing member 94 in the axial direction Lgrasped by a grasping device (not illustrated). In this way, theconductor side portion groups are pressed by the inner pressing members94 toward the radially outer side R2 without passing through theradially opening portions 21 a. Such a pressing device 9 does notinclude the fixed member 91 and the insertion member 93 (see FIG. 7)discussed above, and includes the plurality of inner pressing members 94and the grasping device. Also in the present reference form, thepressing device 9 which includes the plurality of movable members 92,the width of which in the circumferential direction C is smaller thanthat of the radially opening portions 21 a, may be used as in thereference form of the method of manufacturing the stator 1 according tothe fourth embodiment described above.

The manufacturing process S1 for the stator 1 according to the presentembodiment includes a regulation process S15 in place of the pressingprocess S13. In the regulation process S15 according to the presentembodiment, for example, the movable member 92 described above, whichhas the narrow portion 92 b and the wide portion 92 c, or the innerpressing member 94 described above is fixed at a position at which themovable member 92 or the inner pressing member 94 contacts the conductorside portion group, rather than being moved toward the radially outerside R2. Then, the plurality of segment conductors 4 which are disposedin the slot 21 are pressed from both sides in the axial direction L (thefirst axial side L1 and the second axial side L2).

7. Sixth Embodiment

A sixth embodiment will be described below with reference to FIG. 14. Ina reference form of a method of manufacturing the stator 1 according tothe present embodiment, the state of the insulating member 7 during thepressing process S13 is different from that according to the referenceform of the method of manufacturing the stator 1 according to the fourthembodiment described above. The differences from the reference form ofthe method of manufacturing the stator 1 according to the fourthembodiment described above will be mainly described below. The sameelements as those in the reference form of the method of manufacturingthe stator 1 according to the fourth embodiment described above will notbe particularly described.

In the present reference form, as illustrated in FIG. 14, the insulatingmember 7 is disposed so as to cover all the side surfaces of theconductor side portion group. Here, a portion of the insulating member 7that covers the side surface of the conductor side portion group on theside of the radially opening portion 21 a is constituted by foldingportions of the insulating member 7 that extend from portions thatcontact the side surfaces of the conductor side portion group on bothsides in the circumferential direction C toward the radially openingportion 21 a in a direction along the side surface of the conductor sideportion group on the side of the radially opening portion 21 a. In thisportion, portions of the insulating member 7 on both sides in thecircumferential direction C may be disposed so as to overlap each other,or the end portions of the insulating member 7 on both sides in thecircumferential direction C may be disposed so as to contact each other.In the pressing process S13 according to the present reference form, asillustrated in FIG. 11, the pressing device 9 which includes theplurality of movable members 92 according to the reference form of themethod of manufacturing the stator 1 according to the fourth embodimentdescribed above is used. The pressing device 9 described in relation tothe reference form of the method of manufacturing the stator 1 accordingto the fifth embodiment described above may also be used. Themanufacturing process S1 for the stator 1 according to the presentembodiment also includes a regulation process S15 in place of thepressing process S13.

8. Seventh Embodiment

A seventh embodiment will be described below with reference to FIGS. 15to 17. As illustrated in FIG. 15, the manufacturing process S1 accordingto the present embodiment includes a preparation process S10, a jointmaterial arrangement process S11, a regulation member arrangementprocess S16, an insertion process S17, a regulation surface movingprocess S18, a regulation process S15, and a joint process S14. That is,the manufacturing process S1 according to the present embodiment isdifferent from the manufacturing process S1 (see FIG. 9) according tothe third embodiment described above in including the regulation memberarrangement process S16 and the regulation surface moving process S18and including the insertion process S17 in place of the arrangementprocess S12 discussed above. The differences from the third embodimentdescribed above will be mainly described below. The same elements asthose in the third embodiment described above will not be particularlydescribed.

In the regulation member arrangement process S16, the regulation member10 which regulates movement of the conductor side portions 41 in theradial direction R through the regulation surface 11 is disposed. In theregulation member arrangement process S16, as illustrated in FIG. 16,the regulation surface 11 of the regulation member 10 is disposed inaccordance with the position, in the radial direction R, of theconductor side portions 41 positioned most on the side of the radiallyopening portion 21 a (radially inner side R1).

Here, the thickness of one conductor side portion 41 in the radialdirection R is defined as a conductor thickness T1, and a lengthobtained by multiplying the number (eight in the illustrated example) ofthe conductor side portions 41 which are arranged in the radialdirection R in the slot 21 by the conductor thickness T1 is defined asan in-slot conductor thickness T2.

In the regulation member arrangement process S16 according to thepresent embodiment, the regulation surface 11 is located away from theinner wall surface 21 b of the slot 21 on the opposite side (radiallyouter side R2) from the side of the radially opening portion 21 a towardthe radially opening portion 21 a (radially inner side R1) by thein-slot conductor thickness T2 or more. Further, the regulation surface11 is disposed at a position housed in the slot 21. Specifically, theregulation surface 11 is located away from the inner wall surface 21 bby a distance that is less than the slot depth Ds which is the length ofthe slot 21 in the radial direction R. In the illustrated example, theregulation surface 11 is located away from the inner wall surface 21 btoward the radially opening portion 21 a (radially inner side R1) by adistance obtained by adding a prescribed clearance to the in-slotconductor thickness T2. That is, the distance from the inner wallsurface 21 b to the regulation surface 11 is more than the in-slotconductor thickness T2 by the clearance. The distance from the innerwall surface 21 b to the regulation surface 11 may be equal to thein-slot conductor thickness T2 by setting the clearance to zero.

In the present embodiment, as illustrated in FIG. 16, the regulationsurface 11 has a guide inclined surface 12 on both sides in the axialdirection L (the first axial side L1 and the second axial side L2) ofthe regulation surface 11. The pair of guide inclined surfaces 12 areformed so as to be directed toward the radially opening portion 21 a(radially inner side R1) as the guide inclined surfaces 12 extend awayfrom each other. That is, the pair of guide inclined surfaces 12 areformed so as to be spaced more from the inner wall surface 21 b of theslot 21 as the guide inclined surfaces 12 extend away from each other.In the present embodiment, the guide inclined surfaces 12 are formed inparallel with the circumferential direction C.

In the insertion process S17, which is performed after the regulationmember arrangement process S16, at least either the conductor sideportions 41 of the first segment conductor 5 and the conductor sideportions 41 of the second segment conductor 6 are inserted into theslots 21 such that the facing surface 44 of one of the joint portions 43of the first segment conductor 5 and the facing surface 44 of one of thejoint portions 43 of the second segment conductor 6 face each other. Inthe insertion process S17, movement of the conductor side portions 41 inthe radial direction R is regulated by the regulation surface 11 of theregulation member 10 until the facing surface 44 of one of the jointportions 43 of the first segment conductor 5 and the facing surface 44of one of the joint portions 43 of the second segment conductor 6 faceeach other. The insertion process S17 is one form of the arrangementprocess S12 discussed above. In the insertion process S17 according tothe present embodiment, as illustrated in FIG. 16, the conductor sideportions 41 of the plurality of segment conductors 4 are insertedbetween the regulation surface 11 of the regulation member 10 and theinner wall surface 21 b of the slot 21. At this time, in the presentembodiment, the distal end portions of the conductor side portions 41are guided toward the inside of the slot 21 by the guide inclinedsurfaces 12, and therefore the conductor side portions 41 can be easilyinserted between the regulation surface 11 and the inner wall surface 21b.

In the insertion process S17 according to the present embodiment, theplurality of first segment conductors 5 and the plurality of secondsegment conductors 6 are inserted into the slots 21 from both sides inthe axial direction L (the first axial side L1 and the second axial sideL2) such that the facing surface 44 of the first conductor side portion411 of the first segment conductor 5 and the facing surface 44 of thesecond conductor side portion 412 of the second segment conductor 6 faceeach other and the facing surface 44 of the second conductor sideportion 412 of the first segment conductor 5 and the facing surface 44of the first conductor side portion 411 of a different second segmentconductor 6 face each other in each of the slots 21.

In the regulation surface moving process S18, as illustrated in FIG. 17,the regulation surface 11 is moved toward the opposite side (radiallyouter side R2) from the side of the radially opening portion 21 a in theradial direction R. In the present embodiment, the regulation surface 11is formed on the end surface of the regulation member 10 on the radiallyouter side R2, and therefore the regulation surface 11 is moved towardthe opposite side (radially outer side R2) from the radially openingportion 21 a in the radial direction R by moving the regulation member10 toward the opposite side (radially outer side R2) from the radiallyopening portion 21 a in the radial direction R. The configuration of amoving device that moves the regulation member 10 in the radialdirection R is not specifically limited. The moving device may besimilar to a mechanism that moves the movable members 92 of the pressingdevice 9, or other moving devices known in the art may also be adopted.

As illustrated in FIG. 15, the regulation surface moving process S18 isperformed after the insertion process S17 and before the joint processS14. In the present embodiment, the regulation surface moving processS18 follows the insertion process S17, and the regulation process S15follows the regulation surface moving process S18.

In the illustrated example, as discussed above, the distance from theinner wall surface 21 b to the regulation surface 11 is a distanceobtained by adding the prescribed clearance to the in-slot conductorthickness T2. Therefore, when the regulation surface 11 is moved towardthe opposite side (radially outer side R2) from the side of the radiallyopening portion 21 a in the radial direction R, the regulation surface11 contacts the surfaces of the segment conductors 4 on the side of theradially opening portion 21 a with the clearance described aboveeliminated. When the regulation surface 11 is further moved, theregulation surface 11 presses the conductor side portions 41 of theplurality of segment conductors 4 toward the radially outer side R2. Inthis case, the regulation surface moving process S18 and the regulationprocess S15 function as the pressing process S13 discussed above.

The regulation member 10 which is disposed in the regulation memberarrangement process S16 may be the regulation member 10 in a differentshape such as that illustrated in FIG. 10 discussed above. In addition,the regulation member 10 may be shaped similarly to the movable member92 illustrated in FIG. 7.

9. Second Reference Form of Method of Manufacturing Rotary ElectricMachine Armature

A second reference form of a method of manufacturing a rotary electricmachine armature will be described below with reference to FIG. 18. Thepresent reference form is different from the seventh embodimentdescribed above in that the pressing device 9 is disposed in place ofthe regulation member 10 in the regulation member arrangement processS16 as illustrated in FIG. 18. In the present reference form, the endsurfaces, on the radially outer side R2, of the first pressing portion921 and the second pressing portion 922 of the movable member 92 eachfunction as the regulation surface 11.

As illustrated in FIG. 18, the segment conductors 4 according to thepresent reference form are similar to those according to the secondembodiment described above (see FIG. 4). Therefore, the facing surface44 of the segment conductor 4 according to the present reference formincludes a first inclined surface 441, a second inclined surface 442,and a third inclined surface 443. As discussed above, the first inclinedsurface 441 and the second inclined surface 442 form a projectingportion that projects in the radial direction R. Hence, the jointportion 43 of the first segment conductor 5 and the joint portion 43 ofthe second segment conductor 6 have respective radiallyrecessed/projecting portions 45 to be meshed with each other in theradial direction R. In the present reference form, a meshing depth Dewhich is the depth of meshing of the radially recessed/projectionportion 45 is the length of the second inclined surface 442 in theradial direction R.

In the regulation member arrangement process S16 according to thepresent reference form, the regulation surface 11 is located away fromthe inner wall surface 21 b of the slot 21 on the opposite side(radially outer side R2) from the side of the radially opening portion21 a toward the radially opening portion 21 a (radially inner side R1)by a length obtained by adding the meshing depth De to the in-slotconductor thickness T2 or more. Further, the regulation surface 11 isdisposed at a position housed in the slot 21. Specifically, theregulation surface 11 is located away from the inner wall surface 21 bby a distance that is less than the slot depth Ds which is the length ofthe slot 21 in the radial direction R.

In the illustrated example, the regulation surface 11 is located awayfrom the inner wall surface 21 b toward the radially opening portion 21a (radially inner side R1) by a distance that is identical to the lengthobtained by adding the meshing depth De to the in-slot conductorthickness T2. That is, the distance from the inner wall surface 21 b tothe regulation surface 11 is equal to the length obtained by adding themeshing depth De to the in-slot conductor thickness T2. In theillustrated example, the conductor side portions 41 positioned most onthe opposite side (radially outer side R2) from the side of the radiallyopening portion 21 a contact the inner wall surface 21 b of the slot 21.Therefore, the distance between the end surfaces of the first pressingportion 921 and the second pressing portion 922 on the radially outerside R2 and the side surfaces, on the radially inner side R1, of theconductor side portions 41 positioned most on the side of the radiallyopening portion 21 a (radially inner side R1) is equal to the meshingdepth De. That is, a clearance corresponding to the meshing depth De isformed between the first pressing portion 921 and the second pressingportion 922 and the conductor side portions 41 positioned most on theside of the radially opening portion 21 a (radially inner side R1).

In the regulation surface moving process S18 according to the presentreference form, as in the pressing process S13 discussed above, themovable member 92 is moved toward the radially outer side R2.Consequently, the first pressing portion 921 and the second pressingportion 922 approach the conductor side portions 41 positioned most onthe side of the radially opening portion 21 a (radially inner side R1),which reduces the clearance therebetween. In the case where the movablemember 92 is further moved from a state in which the clearance has beeneliminated, the conductor side portions 41 of the plurality of segmentconductors 4 are pressed toward the radially outer side R2. In this way,a transition can be made smoothly from the regulation surface movingprocess S18 to the pressing process S19 (see FIG. 7). The regulationsurface moving process S18 may be ended in a state in which a clearancethat is less than the meshing depth De is formed, rather than moving themovable member 92 until the clearance described above is eliminated inthe regulation surface moving process S18. In this case, the regulationprocess S15 is performed in place of the pressing process S19 after theregulation surface moving process S18.

In addition, as discussed above, the first pressing portion 921 and thesecond pressing portion 922 are formed so as to project toward theradially outer side R2 with respect to portions on both sides in theaxial direction L. Therefore, as illustrated in FIG. 18, a first guideinclined surface 921 a and a second guide inclined surface 922 a areformed on both sides in the axial direction L (the first axial side L1and the second axial side L2) of the movable member 92. Specifically,the first guide inclined surface 921 a is formed on the first axial sideL1 of the first pressing portion 921, and the second guide inclinedsurface 922 a is formed on the second axial side L2 of the secondpressing portion 922. The first guide inclined surface 921 a and thesecond guide inclined surface 922 a are formed so as to be directedtoward the radially opening portion 21 a (radially inner side R1) as thefirst guide inclined surface 921 a and the second guide inclined surface922 a extend away from each other. The first guide inclined surface 921a and the second guide inclined surface 922 a have a function that issimilar to that of the pair of guide inclined surfaces 12 of theregulation member 10 according to the seventh embodiment describedabove.

10. Other Embodiments

(1) In the embodiments described above, the facing surfaces 44 which areeach a single inclined surface are formed at the joint portions 43 ofthe conductor side portions 41 (first embodiment), or the facingsurfaces 44 which each include the first inclined surface 441, thesecond inclined surface 442, and the third inclined surface 443 areformed at the joint portions 43 of the conductor side portions 41(second embodiment), for example. However, the facing surfaces 44 canalso be shaped differently from those according to the embodimentsdescribed above, as described below.

For example, the facing surfaces 44 may be shaped as illustrated in FIG.19. The facing surfaces 44 illustrated in FIG. 19 each include a firstorthogonal surface 445 and a second orthogonal surface 447 that extendalong the radial direction R, that is, a direction that is orthogonal tothe extension direction of the conductor side portions 41, and aparallel surface 446 that extends along the axial direction L, that is,a direction that is parallel to the extension direction of the conductorside portions 41. The first orthogonal surface 445, the parallel surface446, and the second orthogonal surface 447 are disposed in this orderfrom the distal end portion toward the base end portion of the conductorside portion 41 in the axial direction L, and formed to be continuouswith adjacent surfaces. In the present embodiment, the facing surface 44of the first conductor side portion 411 does not have a surface thatfaces the radially inner side R1 and therefore is constituted of only asurface that faces the radially outer side R2, and the facing surface 44of the second conductor side portion 412 does not have a surface thatfaces the radially outer side R2 and therefore is constituted of only asurface that faces the radially inner side R1. Also in the presentembodiment, the facing surfaces 44 which face each other have the sameshape as each other, and are disposed in parallel with each other.

Alternatively, as illustrated in FIG. 20, the facing surfaces 44 whichface each other may be shaped differently from each other. Also in thiscase, it is suitable if the pair of facing surfaces 44 which face eachother are formed with a projection and a recess corresponding to eachother, and the projection and the recess are engaged with each other tohave a positioning function and a function of regulating separation inthe axial direction L. In the example illustrated in FIG. 20, the facingsurfaces 44 are formed with a portion that projects in the radialdirection R or a portion dented in the radial direction R. The pair offacing surfaces 44 configured in this manner also function as theradially recessed/projecting portions 45, as with those according to thesecond reference form described above (see FIG. 18).

(2) In the embodiments described above, the coil 3 includes a pluralityof segment conductors 4 configured to be wound around the stator core 2by lap winding. However, the present disclosure is not limited thereto.For example, the coil 3 may include a plurality of segment conductors 4configured to be wound around the stator core 2 by wave winding.

(3) In the embodiments described above, the cross-sectional shape of thesegment conductors 4 taken along a plane that is orthogonal to theextension direction is rectangular. However, the present disclosure isnot limited thereto. The cross-sectional shape of the linear conductorsmay be a shape other than a rectangular shape. For example, thecross-sectional shape of the linear conductors may be a circular shapeor an elliptical shape, and may be a polygonal shape such as atriangular shape, a pentagonal shape, or a shape with six or more sides.

(4) In the embodiments described above, the slots 21 extend in parallelwith the axial direction L. However, the present disclosure is notlimited thereto. It is also suitable if the slots 21 extend as inclinedwith respect to the axial direction L, either entirely or partially.Also in this case, the slots 21 are considered to extend in the axialdirection L.

(5) In the embodiments described above, in the joint materialarrangement process S11, the conductive joint material 8 is disposed onat least one of the facing surfaces 44, which face each other, of thepair of segment conductors 4, and the pair of joint portions 43 (facingsurfaces 44) are joined to each other using the conductive jointmaterial 8. However, the present disclosure is not limited thereto. Forexample, the pair of joint portions 43 (facing surfaces 44) may bejoined to each other by welding etc. without using a joint material.

In addition, the joint portion 43 of the first segment conductor 5 andthe joint portion 43 of the second segment conductor 6 may be shaped tobe fitted with each other. An example illustrated in FIG. 21 is areference example in which the joint portion 43 of the first segmentconductor 5 and the joint portion 43 of the second segment conductor 6are shaped to be fitted with each other in the radial direction R. Inthe example illustrated in FIG. 21, one of the pair of facing surfaces44 illustrated in FIG. 19 is provided with a radially fitting projectingportion 43 a, and the other is provided with a radially fitting holeportion 43 b. The radially fitting projecting portion 43 a projects inthe radial direction R from the parallel surface 446 of one of thefacing surfaces 44. The radially fitting hole portion 43 b opens in theparallel surface 446 of the other facing surface 44 so as to extend inthe radial direction R into the joint portion 43 which has the otherfacing surface 44. In such a configuration provided with the radiallyfitting projecting portion 43 a and the radially fitting hole portion 43b, the radially fitting projecting portion 43 a is inserted into theradially fitting hole portion 43 b by pressing the pair of conductorside portions 41, which are provided with the radially fittingprojecting portion 43 a and the radially fitting hole portion 43 b, inthe radial direction R with the radially fitting projecting portion 43 aand the radially fitting hole portion 43 b facing each other in thepressing process S13. Consequently, the radially fitting projectingportion 43 a and the radially fitting hole portion 43 b are fitted witheach other, and the joint portion 43 of the first segment conductor 5and the joint portion 43 of the second segment conductor 6 are joined toeach other. The length of the radially fitting projecting portion 43 ain the radial direction R is set to be equal to or less than the lengthof the radially fitting hole portion 43 b in the radial direction R. Inthe example illustrated in FIG. 21, in addition, the radially fittinghole portion 43 b penetrates the joint portion 43 in the radialdirection R. The shape of the radially fitting projecting portion 43 aand the radially fitting hole portion 43 b is not specifically limited.It is only necessary that the radially fitting projecting portion 43 aand the radially fitting hole portion 43 b should be shaped such thatthe former can be inserted into the latter in the radial direction R.Examples of the shape of the radially fitting projecting portion 43 aand the radially fitting hole portion 43 b include a circular columnshape and a rectangular column shape.

The joint portion 43 of the first segment conductor 5 and the jointportion 43 of the second segment conductor 6 may be shaped to be fittedwith each other in the axial direction L. In the example illustrated inFIG. 22, one of the pair of facing surfaces 44, which are formed as flatsurfaces that extend along the radial direction R, is provided with anaxially fitting projecting portion 43 c, and the other is provided withan axially fitting hole portion 43 d. The axially fitting projectingportion 43 c projects in the radial direction R from one facing surface44. The axially fitting hole portion 43 d opens in the other facingsurface 44 so as to extend in the axial direction L into the jointportion 43 which has the other facing surface 44. In such aconfiguration provided with the axially fitting projecting portion 43 cand the axially fitting hole portion 43 d, as in the third embodimentdescribed above (see FIG. 8) and the seventh embodiment described above(see FIG. 17), the axially fitting projecting portion 43 c is insertedinto the axially fitting hole portion 43 d by pressing the plurality ofsegment conductors 4, which are provided with the axially fittingprojecting portion 43 c and the axially fitting hole portion 43 d, inthe axial direction L with the axially fitting projecting portion 43 cand the axially fitting hole portion 43 d facing each other in the jointprocess S14. Consequently, the axially fitting projecting portion 43 cand the axially fitting hole portion 43 d are fitted with each other,and the joint portion 43 of the first segment conductor 5 and the jointportion 43 of the second segment conductor 6 are joined to each other.The length of the axially fitting projecting portion 43 c in the axialdirection L is set to be equal to or less than the length of the axiallyfitting hole portion 43 d in the axial direction L. The shape of theaxially fitting projecting portion 43 c and the axially fitting holeportion 43 d is not specifically limited. It is only necessary that theaxially fitting projecting portion 43 c and the axially fitting holeportion 43 d should be shaped such that the former can be inserted intothe latter in the axial direction L. Examples of the shape of theaxially fitting projecting portion 43 c and the axially fitting holeportion 43 d include a circular column shape and a rectangular columnshape.

The conductive joint material 8 may be disposed between the jointportions 43 of the pair of segment conductors 4 also in the case wherethe joint portions 43 are shaped to be fitted with each other in theradial direction R or the axial direction L as described above.

(6) In the embodiments described above, the segment conductors 4 areformed in a U-shape as viewed in the radial direction R, and each have apair of conductor side portions 41 and a crossover portion 42 thatconnects between the pair of conductor side portions 41. However, theshape of the segment conductors 4 is not limited thereto. For example,the segment conductors 4 may be formed in a J-shape, and each have oneconductor side portion 41 and a crossover portion 42 connected to theconductor side portion 41.

(7) In the embodiments described above, the rotary electric machinearmature is constituted as the stator 1 for a rotary electric machine ofan inner rotor type. However, the present disclosure is not limitedthereto. The rotary electric machine armature may be constituted as astator 1 for a rotary electric machine of an outer rotor type. In thiscase, it is suitable if the radially opening portions 21 a of the slots21 of the stator core 2 open toward the radially outer side R2.

(8) In the embodiments described above, the joint portions 43 of thefirst segment conductors 5 and the joint portions 43 of the secondsegment conductors 6 are joined to each other in the slot 21. However,the joint portions 43 of the first segment conductors 5 and the jointportions 43 of the second segment conductors 6 may be joined to eachother outside the slot 21 as described below.

In the example illustrated in FIGS. 23 and 24, the pair of conductorside portions 41 of the first segment conductor 5 have the same lengthin the axial direction L, and the pair of conductor side portions 41 ofthe second segment conductor 6 have the same length in the axialdirection L. The conductor side portions 41 of the second segmentconductor 6 are longer in the axial direction L than the conductor sideportions 41 of the first segment conductor 5. The conductor sideportions 41 of the second segment conductor 6 are longer in the axialdirection L than the slots 21. In the case where the second segmentconductor 6 is disposed in the slots 21, the joint portions 43 of theconductor side portions 41 are positioned on the first axial side L1with respect to the end portions of the slots 21 (stator core 2) on thefirst axial side L1. In this manner, in the example illustrated in FIGS.23 and 24, the joint portions 43 of the first segment conductor 5 andthe joint portions 43 of the second segment conductor 6 are joined toeach other outside the slot 21. With such a configuration, the jointportions 43 to be joined to each other cannot be pressed toward theinner wall surface 21 b of the slot 21 on the radially outer side R2 inthe pressing process S13 (see FIG. 7). In addition, movement in theradial direction R of the conductor side portions 41 positioned outsidethe slot 21 (here, the conductor side portions 41 of the first segmentconductor 5) cannot be regulated utilizing the inner wall surface 21 bof the slot 21 on the radially outer side R2 in the regulation processS15 (see FIG. 8) and the insertion process S17. Therefore, it issuitable if movement in the radial direction R of the conductor sideportions 41 positioned outside the slot 21 is regulated using a jig etc.that has portions that face, from the radially outer side R2, theconductor side portions 41 positioned outside the slot 21 and positionedmost on the radially outer side R2.

(9) The configuration disclosed in each of the embodiments discussedabove may be applied in combination with a configuration disclosed inany other embodiment unless any contradiction occurs. Also regarding theother configurations, the embodiment disclosed herein is merelyillustrative in all respects. Thus, a variety of alterations can bemade, as appropriate, without departing from the scope and spirit of thepresent disclosure.

11. Overview of Above Embodiments

The overview of the method (S1) of manufacturing the rotary electricmachine armature (1) described above will be described below.

There is provided

a method (S1) of manufacturing a rotary electric machine armature (1)that includes a cylindrical armature core (2) in which a plurality ofslots (21) that extend in an axial direction (L) are disposed in acircumferential direction and a coil (3) wound around the armature core(2), the slots (21) having respective radially opening portions (21 a)that open in a radial direction (R), and the coil (3) being constitutedby joining a plurality of segment conductors (4) to each other, themethod (S1) including:a preparation step (S10) of preparing a plurality of the segmentconductors (4) and preparing the armature core (2), the segmentconductors (4) having respective conductor side portions (41) thatextend along the axial direction (L) and respective crossover portions(42) connected to the conductor side portions (41) on an outer side ofthe armature core (2) in the axial direction (L), the conductor sideportions (41) being provided with respective joint portions (43) thathave respective facing surfaces (44);an arrangement step (S12) of arranging, when the segment conductor (4),among the plurality of segment conductors (4), the crossover portion(42) of which is disposed on one side (L1) in the axial direction (L)with respect to the armature core (2), is defined as a first segmentconductor (5) and the segment conductor (4), the crossover portion (42)of which is disposed on the other side (L2) in the axial direction (L)with respect to the armature core (2), is defined as a second segmentconductor (6), at least either the conductor side portions (41) of thefirst segment conductor (5) or the conductor side portions (41) of thesecond segment conductor (6) in the slots (21) such that the facingsurface (44) of one of the joint portions (43) of the first segmentconductor (5) and the facing surface (44) of one of the joint portions(43) of the second segment conductor (6) face each other;a regulation step (S15) of regulating movement of the conductor sideportions (41) in the radial direction (R); anda joint step (S14) of joining the joint portion (43) of the firstsegment conductor (5) and the joint portion (43) of the second segmentconductor (6) to each other by pressing at least one of the firstsegment conductor (5) and the second segment conductor (6) in the axialdirection (L) such that the first segment conductor (5) and the secondsegment conductor (6) approach each other while maintaining a regulatingstate in the regulation step (S15).

With this configuration, movement of the conductor side portions (41) ofthe segment conductors (4) in the radial direction (R) is regulated.Therefore, displacement and separation of the joint portions (43) of thefirst segment conductor (5) and the joint portions (43) of the secondsegment conductor (6) from each other in the radial direction (R) can berestricted when such joint portions are to be joined to each other bypressing the first segment conductor (5) and the second segmentconductor (6) in the axial direction (L). Thus, the segment conductors(4) can be easily joined to each other appropriately.

Preferably, the arrangement step (S12) includes arranging both theconductor side portions (41) of the first segment conductor (5) and theconductor side portions (41) of the second segment conductor (6) in theslots (21); and

the joint step (S14) includes joining the joint portions (43) of thefirst segment conductor (5) and the joint portions (43) of the secondsegment conductor (6) to each other in the slots (21).

In this configuration, both the conductor side portions (41) of thefirst segment conductor (5) and the conductor side portions (41) of thesecond segment conductor (6) are disposed in the slots (21). Therefore,movement of the conductor side portions (41) in the radial direction (R)can be regulated utilizing the inner wall surfaces (21 b) of the slots(21). Thus, displacement and separation of the joint portions (43) ofthe first segment conductor (5) and the joint portions (43) of thesecond segment conductor (6) from each other in the radial direction (R)can be easily restricted when such joint portions are to be joined toeach other.

Preferably, the method (S1) further includes a joint materialarrangement step (S11) of disposing a conductive joint material (8) onat least one of the facing surfaces (44) which face each other, theconductive joint material (8) joining the joint portions (43) of thefirst segment conductor (5) and the joint portions (43) of the secondsegment conductor (6) to each other while securing conductivity; and

the joint step (S14) includes joining the joint portions (43) of thefirst segment conductor (5) and the joint portions (43) of the secondsegment conductor (6) to each other by heating the conductive jointmaterial (8).

With this configuration, the segment conductors (4) can be joined toeach other appropriately by the conductive joint material (8) whilesecuring conductivity.

Preferably, the joint portions (43) of the first segment conductor (5)and the joint portions (43) of the second segment conductor (6) areshaped to be fitted with each other in the axial direction (L); and

the joint step (S14) includes fitting the joint portions (43) of thefirst segment conductor (5) and the joint portions (43) of the secondsegment conductor (6) with each other to be joined by pressing at leastone of the first segment conductor (5) and the second segment conductor(6) in the axial direction (1) such that the joint portions (43) of thefirst segment conductor (5) and the joint portions (43) of the secondsegment conductor (6) approach each other in the axial direction (L).

In this configuration, the joint portions (43) of the first segmentconductor (5) and the joint portions (43) of the second segmentconductor (6) are fitted with each other to be joined. Thus, the jointportions (43) of the first segment conductor (5) and the joint portions(43) of the second segment conductor (6), which are joined to eachother, cannot be easily separated from each other.

Preferably, the regulation step (S15) includes disposing a regulationmember (10) on a side of the radially opening portion (21 a) withrespect to the conductor side portion (41) positioned most on the sideof the radially opening portion (21 a) in the slot (21); and

the regulation member (10) has a regulation surface (11) that faces theconductor side portion (41) and that regulates movement of the conductorside portion (41) in the radial direction (R).

In this configuration, the regulation member (10) is disposed such thatall the conductor side portions (41) in the slot (21) are positionedbetween the regulation surface (11) and the inner wall surface (21 b) ofthe slot (21) on the opposite side from the side of the radially openingportion (21 a). Thus, movement of the conductor side portions (41) inthe radial direction (R) can be regulated with a simple configuration.

Preferably, the regulation surface (11) is formed so as to face anobject region (OA) which is an entire region or a part of a region, inthe axial direction (L), of both the conductor side portions (41) of thefirst segment conductor (5) and the conductor side portions (41) of thesecond segment conductor (6), and is shaped along a surface of theobject region (OA) that faces the regulation surface (11).

With this configuration, movement in the radial direction (R) of theobject region (OA), which is set in the entire region or a part of theregion of the conductor side portions (41) in the axial direction (L),can be regulated appropriately by the regulation surface (11) whichfaces the object region (OA). Here, the regulation surface (11) isshaped along the object region (OA) of the conductor side portions (41).Thus, movement of the conductor side portions (41) in the radialdirection (R) can be regulated stably by such a regulation surface (11).

Preferably, the joint step (S14) includes fixing the regulation surface(11) in position in the radial direction (R).

With this configuration, the regulation member (10) is not moved in theradial direction (R) in the joint step (S14). Thus, the regulating stateof the conductor side portions (41) by the regulation member (10) can bemaintained appropriately in the joint step (S14).

INDUSTRIAL APPLICABILITY

The technology according to the present disclosure can be utilized for amethod of manufacturing a rotary electric machine armature that includesa cylindrical armature core in which a plurality of slots that extend inthe axial direction are disposed in the circumferential direction and acoil wound around the armature core.

1. A method of manufacturing a rotary electric machine armature thatincludes a cylindrical armature core in which a plurality of slots thatextend in an axial direction are disposed in a circumferential directionand a coil wound around the armature core, the slots having respectiveradial openings that open in a radial direction, and the coil beingformed by joining a plurality of segment conductors to each other, themethod comprising: preparing a plurality of the segment conductors andpreparing the armature core, the segment conductors having respectiveconductor side portions that extend along the axial direction andrespective crossover portions connected to the conductor side portionson an outer side of the armature core in the axial direction, theconductor side portions being provided with respective joint portionsthat have respective facing surfaces; arranging, when the segmentconductor, among the plurality of segment conductors, the crossoverportion of which is disposed on one side in the axial direction withrespect to the armature core, is defined as a first segment conductorand the segment conductor, the crossover portion of which is disposed onthe other side in the axial direction with respect to the armature core,is defined as a second segment conductor, at least either the conductorside portions of the first segment conductor or the conductor sideportions of the second segment conductor in the slots such that thefacing surface of one of the joint portions of the first segmentconductor and the facing surface of one of the joint portions of thesecond segment conductor face each other; regulating movement of theconductor side portions in the radial direction; and joining the jointportion of the first segment conductor and the joint portion of thesecond segment conductor to each other by pressing at least one of thefirst segment conductor and the second segment conductor in the axialdirection such that the first segment conductor and the second segmentconductor approach each other while maintaining a regulating state. 2.The method of manufacturing according to claim 1, wherein: the arrangingincludes arranging both the conductor side portions of the first segmentconductor and the conductor side portions of the second segmentconductor in the slots; and the joining includes joining the jointportions of the first segment conductor and the joint portions of thesecond segment conductor to each other in the slots.
 3. The method ofmanufacturing according to claim 1, further comprising: disposing aconductive joint material on at least one of the facing surfaces whichface each other, the conductive joint material joining the jointportions of the first segment conductor and the joint portions of thesecond segment conductor to each other while securing conductivity,wherein the joining includes joining the joint portions of the firstsegment conductor and the joint portions of the second segment conductorto each other by heating the conductive joint material.
 4. The method ofmanufacturing according to claim 1, wherein the joint portions of thefirst segment conductor and the joint portions of the second segmentconductor are shaped to be fitted with each other in the axialdirection; and the joining includes fitting the joint portions of thefirst segment conductor and the joint portions of the second segmentconductor with each other to be joined by pressing at least one of thefirst segment conductor and the second segment conductor in the axialdirection such that the joint portions of the first segment conductorand the joint portions of the second segment conductor approach eachother in the axial direction.
 5. The method of manufacturing accordingto claim 1, wherein: the regulating includes disposing a regulationmember on a side of the radial opening with respect to the conductorside portion positioned most on the side of the radial opening in theslot; and the regulation member has a regulation surface that faces theconductor side portion and that regulates movement of the conductor sideportion in the radial direction.
 6. The method of manufacturingaccording to claim 5, wherein the regulation surface is formed so as toface an object region which is an entire region or a part of a region,in the axial direction, of both the conductor side portions of the firstsegment conductor and the conductor side portions of the second segmentconductor, and is shaped along a surface of the object region that facesthe regulation surface.
 7. The method of manufacturing according toclaim 5, wherein the joining includes fixing the regulation surface inposition in the radial direction.